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By Janene Barter

Telfer Gold Mine treats both gold/copper oxide and sulfide ores in a remote location in the Great Sandy Desert, Western Australia. Currently, the oxide gold ore is treated in a conventional CIL circuit by blending the low and high grade copper ores to minimise cyanide consumption and allow smooth operation. The sulfide ore is treated through a flotation circuit to produce pyrite and copper concentrates. The pyrite concentrate is treated in the CIL. Copper concentrate is stockpiled and sold to a smelter for further processing. In recent times, as the depth of the pit has increased the copper head grade has also increased, to the point where the ore was becoming uneconomical to treat. In addition, it was desirable to reduce the amount of cyanide reporting to the tails dam both from an environmental and economical viewpoint. Newcrest Mining Limited engaged GRD Minproc Limited to evaluated a process to reduce the amount of cyanide entering the tail dam with consideration given to copper recovery. From this investigation, the Sulfidisation, Acidification, Recycle and Thickening (SART) process was selected. A detailed testwork program for SART was undertaken with the objective to design and construct a SART plant at Telfer. This paper outlines how the SART process was chosen and summarises the testwork that led to the design of the SART plant. It also touches on some of the important issues for designing this type of process.

Jan 1, 1998

By W. H. (Bill) Jay

The destruction of cyanide creates a significant impost on the financial returns of gold mines. These losses increase substantially when ores containing cyanide-soluble copper are treated. Failure to remove or destroy free or WAD cyanide before it is discharged into tailings dams has, on a number of occasions, led to significant fish, bird and animal deaths. Thus, the retention of cyanide within the leach circuit and the recovery or removal of stable metal cyanide complexes needs to become standard practice for all gold mining operations. Furthermore, reducing cyanide purchases will minimise the quantity of cyanide transported to the mine site thereby reducing the opportunity for spillage of this chemical. Many different physical and chemical methods have been investigated for the removal of cyanide from process solutions. All cyanide destruction methods create a financial impost on the economic viability of the gold mine. To reduce these costs, the recycle of cyanide and the economic recovery of the metals solubilised by cyanide is of prime importance. The alternative methods currently in use, or under consideration for the treatment of copper cyanide, entail high reagent costs, produce the recovered metal in a contaminated form and require the safe handling of hydrogen cyanide. These processes will be briefly discussed within this report Environmental and financial benefits are enhanced by recent laboratory and pilot plant studies conducted by Oretek Limited. The Oretek CPC process for the recovery of copper and the recycle of cyanide from copper cyanide-containing solutions does not require pH adjustment to the alkaline cyanide leach conditions. Copper ions are coordinated to a water-soluble and/or an organic soluble polychelating agent under alkaline conditions and the cyanide ions are displaced Membrane separation, or phase separation of the polychelated copper from the cyanide ions enables the cyanide ions to be recycled and the copper to be directly electrowon from the polychelating polymer. The polychelating polymer is then recycled. Ion exchange resins and solvent extraction systems which may be incorporated into the above process will also be discussed in detail.

Jan 1, 1998

By J. R. Batista, J. C. Young

Leachates from gold heap-leaching mines may contain selenium concentrations as high as 2 mg/L. Previous studies report satisfactory selenium adsorption by activated alumina from relatively "clean" drinking waters. However, the findings of these studies cannot be directly applied to the treatment of mine leachate where other ions compete for the alumina adsorption sites. This study evaluated the adsorption of selenium from a mine leachate to develop design parameters for a full-scale activated alumina process. The study revealed that 68% of the selenium in the leachate could be removed by alumina at pH levels greater than 5.0. At pH levels less than 4, silica was poorly adsorbed by alumina, and selenium adsorption was improved. Silica adversely affected the selenium adsorption capacity.

Jan 1, 1998

By Shane Andrews, Gustavo Vasquez, S. K. Varma

"The effect of solutionizing time on the corrosive wear behavior of 2014 aluminum alloy has been studied using the impact and continuous mode of scratching techniques. The transient currents (TC) evolved during the scratching of the alloy shows a linear dependence between the TC and the solutionizing time. Higher TC values at longer solutionizing time may be associated with the changes in the concentration of quenched-in vacancies, grain sizes and dislocations generated during scratching. These factors can either create (a) anodic sites or (b) pitting corrosion resulting in the generation of transient currents. The results have been compared with the similar study carried out for 6061 aluminum alloys. This 6061 aluminum alloy shows similar behavior but the rate of TC generation per unit solutionizing time is much lower than 2014 aluminum alloy. The morphological changes in the impact scratches and the TEM investigation in the scratch have been presented in this paper.IntroductionThe technique of studying corrosive wear of composites of 6061 aluminum in the monolithic and reinforced forms has been reported in the literature [1]. Two modes of scratching, consisting of impact and continuous, in a corrosive environment indicate that the composites, containing 0.10 and 0.20 volume fractions of alumina particles (VFAP), have higher corrosive wear rates than the monolith. A graph between the transient current (TC) generated during the impact scratching as a function of solutionizing time at 540°C indicates linear relationship between them. A similar slopes for the composites were observed and the TC values were less for the composite containing lesser VFAP."

Jan 1, 1998

By M. F. Almeida

"Due to the randomness of all factors influencing the sintering operation, a two-stepped procedure is proposed to find the best way of using stocked fines at a plant producing Fe-Mn alloys for the steelmaking industry. The approach is based on the following: (1) predict the result of the sintering operation by establishing the best multilinear regression model using some of the characteristics of the loaded material; and (2) find the best solution under a minimizing cost criteria by solving a linear optimization problem using the regression equation plus constraints on the feed and product. IntroductionSome tests carried out using 20% to 30% of sinter in the material loaded into a 60 000 KVA Tysland-Hole electric furnace producing Fe-Mn alloys for the steelmaking industry indicated: (1) a meaningful decrease in the off-gas temperature and, consequently, a better energy use due to the material higher porosity; (2) more uniform heat distribution as a consequence of the electrode reaction zone enlargement; (3) an improved furnace control resulting in a smoother operation; and (4) a decrease in gas production facilitating the off-gas treatment. For some years, this plant used only the coarse fraction of the Mn ores, thus stocking all the received and own-generated fine particles. In view of the mentioned results, a strategy for increasing the use of stocked fines was formulated, including a step where it was necessary to decide which components and respective quantities should be used in the blends to be sintered (Almeida, 1984).It is well known that several factors affect productivity and energy consumption in sinter production, also influencing the product quality. Raw materials characteristics, namely chemical and size composition, affect permeability to gases and may or may not allow a deeper bed. In general, finer ores decrease permeability, increasing electricity consumption by fans, but due to their higher specific surface area, react more completely with other components in the mixture. For coke granulometry, a compromise must be obtained in order not to burn it too quickly nor to widen the flame front, therefore decreasing productivity. Decreasing coke in the blend also acts in sinter bonding, decreasing its consistency and increasing crushing and return fines. Moisture addition also influences components mixing, pre-agglomeration, bed permeability and, consequently, sintering productivity. Therefore, optimum conditions must be established for both a given sintering plant and the components in the feed (Dawson, 1993)."

Jan 1, 1998

By A. Perry

Latin America is in the path of economic growth characterized by increased privatization, joint-venture projects, and reduced trade barriers. Privatization is changing the industrial operating mode from Government-owned/Government-operated to a privately-owned/government-regulated regime. The establishment of joint ventures, such as in construction and management of infrastructure, energy and mining projects, and deregulated industries (electricity/gas/ telecommunications), is now a common practice in the region. These changes, coupled with the growing awareness of environmental protection issues, have led to a sincere effort on the part of the countries of Latin America to establish reasonable environmental regulations and controls (RERCs) for all industries, including mining and energy, for the benefit of present and future generations. However, RERCs require further consideration of many factors with respect to environmental, geologic, economic, and social impacts in the region. The process must find a balance between the need to sustain profitable operations and the need to adequately protect the environment. While striving to find a balance between continued industrial profitability and environmental protection, the RERCs must be scientifically sound, pragmatic, flexible, and enforceable. There has been worldwide attention focused on the environment, and international symposia have been held on such issues as global warming, water pollution, air pollution, and hazardous wastes. Organizations such as the United Nations (UN) and the Organization of American States have performed rather extensive studies on the environment for various industries and activities, and have developed some broad general plans to address environmental concerns. This technical information is available for the asking, and should be considered a starting point for countries embarking on the passage and enforcement of their own RERCs.

Jan 1, 1998

By K. Lapakko

Kinetic tests results are influenced by methodological variables, including test duration and mine waste particle size. Some samples tested produced neutral drainage in kinetic tests for more than two years prior to drainage acidification. The potential for long "lag times" can be assessed based on the mine waste mineralogy. The lag time duration can be estimated using this mineralogy in conjunction with dissolution rates observed in the kinetic tests. The influence of particle size on the drainage quality is dependent on the variation of the availability of acid-producing and acid-neutralizing minerals with particle size.

Jan 1, 1998

A comprehensive understanding of the effects of autoclave configuration (batch, semi-batch, continuous) on the residence time necessary to achieve a target conversion is a prerequisite for design of commercial scale autoclaves. Particle size distribution, mineral and reagent concentrations, temperature and mixing also influence the conversion. This paper outlines the bases of using test data to predict performance of commercial scale autoclaves. Recommendations for coordinating test program design with selection of scale-up method are provided. Examples are given to illustrate the different levels of engineering effort needed to meet corresponding levels of design optimization and accuracy.

Jan 1, 1998

By Evan Boone, Peter Bellairs

A technical services visit was conducted to determine the initial parameters to successfully presplit several benches for an input crusher installation at the Wolffdene quarry. The paper details the preliminary design utilising both detonating cord only and specialised presplit product charges and compares these to the final designs utilised based on site experience. The role of accurate drilling, explosive loading and geology in obtaining successful cost effective presplits is highlighted.

Jan 1, 1998

By J. M. Applegate

In the same way that a blueprint communicates information about a structure, a useful systems architecture should provide information that guides the construction and implementation of computing systems. Taking the blueprint analogy a step further, a plot plan can also show where in the "bigger picture" a particular design fits (if in fact it does) and what a builder needs to know about the environment in which he or she will operate. In the context of business systems, a meaningful architecture should convey the following: 1. The primary purpose of computer based systems relative to particular task or operation. 2. The relationship of systems to each other and an indication of their interaction and dependencies. 3. The relationship of systems relative to the organization and its objectives. 4. Indications of where IS/IT resources can best be allocated to support the organization. 5. The overall context in which new systems and technologies can be assessed for both their impact on current system and on the organization itself.

Jan 1, 1998

By D. W. Hendrickson

Cliffs views the process as extending from mine planning to cargo loading including auxiliary systems such as material handling and plant utilities. Process automation is recognized as an area that can provide significant improvement opportunities with less capital requirement than major flowsheet modifications. This paper discusses the development and results of a strategy to allow and promote implementation of process automation improvements at individual mines based on their economic priorities taking advantage of common systems and concepts for use at multiple mines where practical. Specific process control upgrade projects a Hibbing Taconite Company and the Empire Mine are reviewed in detail.

Jan 1, 1998

By Courtney A. Young

Cyanide is a critically important chemical to the mining and metallurgical industry. It has a strong affinity for metals making it favorable as an agent for metal finishing and treatment as well as a lixiviant for metal leaching, particularly gold. These technologies are environmentally sound but, because cyanide is very toxic, safeguards are required to prevent accidental spills and treat effluents before being discharged. Various methods of cyanide remediation by separation and destruction for cyanide management purposes are therefore reviewed. The methods have been broadly categorized as physical, -adsorption. complexation and oxidation methods including photolysis and other advanced-oxidation processes. Reaction mechanisms for these methods are presented throughout this paper, Finally, the methods are compared in regards to their effectiveness in treating various cyanide species: free cyanide, thiocyanate, weak-acid dissociables, and strong-acid dissociables.

Jan 1, 1998

By A. Dale Wunderlich

With the price of precious metals at an 18-year low, every ounce of metal produced is important. The theft of metals from mining and refining sites can mean the diffrence between profit and loss for many mining companies. Low metal prices do not reduce the potential for the theft of precious metals. History has shown that the price of gold has little to do with the desire for employees to steal precious or base metals. There is actually evidence that the theft of precious metals increases when the price of this commodity goes down. Several of the major precious metal thefts in the past year took place at silver mines when the price of silver was less than 16 cents/g ($5/oz). How does the lowest gold price in 18 years affect the need for security at precious metals properties? There is no short answer to this question. One reason is because the exposure to theft of precious metals is unique to each property. This makes it important that each property be evaluated individually. More than 95% of all precious metals thefts can be attributed to those working at the mine site. So preventing employee theft is the primary concern. One consideration is the location of the property. Gold selling at any price is still an attractive commodity in countries where the employees are making between US$400 and US$600 a month. It is not uncommon for employees at mines in countries where low wages are the norm to consider the value of a gram or two of gold to be a significant amount of money. A gram or two of gold a day may not seem like much. But if 15 employees steal two grams a day, that equates to a significant amount of money during a year. The type of property where the precious metals product is being recovered is also important. For example, a property with a gravity circuit is more likely to suffer from the theft of gold product than a property where all gold is finely disseminated and the only gold seen in the ore body is through a microscope. Gravity circuits increase an operation's exposure to theft because the grinding circuit that is associated with a gravity circuit often becomes a giant concentrator. Areas such as the bottom of grinding-mill pump boxes, cyclone-feed-pump clean out traps and the sumps often become locations where precious metals concentrate (Figs. 1 and 2). Muck concentrations in these locations can be as high as 25% to 40% of gold or silver. Not long ago, muck was removed from a barren-solution sump at a Merrill Crowe circuit that had concentrated to more than 40% gold. At a milling site in the Pacific Rim, residents of the community adjacent to the mine learned about the value of the concentrates in the sump under the ball mill and committed an armed rob¬bery. While several of their co-conspirators held the em¬ployees at bay with machetes, the others emptied the contents of the sump into buckets and removed it from the site. Armed robbery is not as common as employee theft. However, while this article was being written, an armed robbery occurred at a gold property in Central America. Armed perpetrators took as hostages the night shift employees at a process plant and used cutting torches that were on site to cut into the high-security and gold-storage areas. The perpetrators then stole a company vehicle to remove the stolen gold buttons and sludge from the site. Unfortunately, this type of activity goes on regularly. But managements of most mining companies are reluctant to discuss theft scenarios. So information pertaining to the theft of precious metals seldom becomes a newsworthy item. An audit conducted at a mine site with a gravity circuit recommended that the gravity recovery area be shut down until adequate protection could be provided. Although it was not connected with the audit, it was necessary to shut down the gravity area for a pro¬longed period because of problems with the gravity table. In the two months that followed, gold production at the site increased by about 31 kg/month (1,000 oz/month). It is difficult to attribute all of this increase to the theft of concentrates. But there was a good chance that at least part of the increase was due to the fact that concentrates were being stolen from the gravity area.

Jan 1, 1998

By Daniel K. Kim

The charge for the copper refinery is a mixture of anodes produced at San Manuel from BHP source concentrate and copper purchased from external sources. Control of unwanted impurities in the tankhouse - is very important and beneficial. Currently available removal/recovery technologies were reviewed for the control of bismuth and antimony levels in the electrolyte. Recent studies have focused on solvent extraction (SX) technology and generated successful results for the removal and subsequent recovery of bismuth and antimony. The SX system employs the reagent, ACORGA SBX-50, in conjunction with a patented high chloride stripping system. The latter enables recycle of the eluant, avoiding the high costs associated with conventional systems, such as regeneration of resin. Concerns over potential transfer of organics and chloride ion to the electrolyte were readily addressed, solved and demonstrated using conventional, established technology. This paper describes the benefits of electrolyte purification, the flexibility afforded by the SX system, the operational practices necessary for maintaining adequate control of bismuth and antimony impurities in the electrorefining environment and possibilities for future development /exploitation of the Zeneca SX system at the San Manuel refinery.

Jan 1, 1998

By Mostafa Benzaazoua, Bruno Bussière, Jean Lelièvre

De nombreuses opérations mimères exploitent et traitent des minerais sulfurés pour concentrer des métaux precieux (Au, Ag ... ) OU des métaux de base (Cu, Pb, Zn ... ), laissant en fin de parcours des tonnages considérables de résidus plus ou moins générateurs de drainage minier acide (DMA) selon leur contenu en sulfures. De nos jours, Jes restrictions en matière de protection de l'environnement obligent Jes opérateurs miniers a trouver Jes solutions Jes plus efficaces pour préserver Jes sites environnants de la pollution due a l'oxydation des sulfures. Cette oxydation cause une acidification accrue du milieu et une mise en solution des metaux toxiques. L'utilisation des recouvrements multicouches est l'une des solutions Jes plus efficaces pour limiter la pollution liée au DMA mais entraine des coilts de construction qui sont souvent considérés par l'industrie miniere comme prohibitifs. Une façon de rendre cette technologie applicable, d'un point de vue économique, est de désulfurer Jes résidus à l'usine de traitement et d'utiliser la fraction inerte comme composante d'un recouvrernent multicouche. Cette opération de desulfuration peut etre réalisée par flottation non sélective des résidus dans le but d'obtenir d'une part un faible volume de concentré de sulfures qui devra être géré convenablement et d'autre part un rejet non générateur d'acide.

Jan 1, 1998

By Jose R. Parga

In mining operations, cyanidation is the ,predominant method by which gold and silver are recovered from their ores and it is recognized that cyanide consumption can be a major factor that contributes to the operating costs for such operations. Also after extraction and recovery of precious metals a certain amount of cyanide is delivered to the tailings pond and must be considered with respect is environmental problems due to the toxicity of cyanides. In this regard, the Air-Sparged Hydrocyclone (ASH) has been used as a reactor for the treatment of cyanide solutions in two ways; first for cyanide recovery by acidulation using the Mexican modification of the Mills-Crowe process and second for cyanide destruction by oxidation with the use of chlorine dioxide (ClO2). In both cases, excellent performance can be achieved using the high capacity ASH system.

Jan 1, 1998

By D. W. Collins

The uptake of gold from halide solutions by activated carbon has been investigated using various techniques. Halide systems typically exhibit combined adsorption-reduction type behavior. In an attempt to gain more information about the nature of these processes, samples of synthetic highly-oriented pyrolytic graphite (HOPG) were contacted with aqueous solutions of gold-iodide. HOPG represents a model structure for activated carbon comprising of basal- plane sites, edge sites, and various defect sites. Two basic instrumental methods were used to examine the uptake of gold by HOPG. The first was standard X-ray photoelectron spectroscopy (XPS). The other involved several scanning probe techniques. XPS clearly indicated a preferred uptake of gold at edge sites. However, iodine appeared to be distributed on both basal-plane and edge sites. At low iodine additions, tapping mode AFM showed that clusters were concentrated along steps and surface defects. At high iodine concentrations, the HOPG surface was uniformly covered by iodine.

Jan 1, 1998

Two key elements in the design of a pastefill or high density hackfill system are the preparation of the backfill material and its distribution underground. This paper examines these two areas. Owing to the essentially impervious nature of total mill tailings, preparation of pastefill and high density fill from current tailings involves a physical dewatering process. There are currently three methods available for this process: I. Vacuum or pressure filters. These represent the 'traditional' approach to the preparation of pastefill. 2. Paste production storage mechanism. This is a thickening/storage mechanism developed with the specific objective of producing paste/high density backfills. 3. Fluidization. This system utilises silos fitted with simple dewatering devices and nozzles. Recently developed by CANMET, it provides the simplest and most economical approach. This paper describes and compares the three preparation methods, from a practical and an economic point of view. Once the pastefill/high density fill has been prepared and binder added, the backfill must be distributed underground into the stopes. A fundamental factor in the design of a distribution system is the rheology of the material- No two materials will exhibit the same properties, and a sequence of rheological and related testing is required prior to the completion of the design of the underground distribution system. This paper covers the testwork normally required and discusses the fundamental design parameters of pastefill distribution systems. The final section of this paper summarises the use of pastefill at three mincsin Canada.

Jan 1, 1998

By Lock PR

The Silver Swan nickel mine is located at the Black Swan Nickel Project, 53 kin north east of Kalgoorlie, Western Australia. The Silver Swan orebody is a massive sulphide nickel deposit dipping 70¦ east with an average in situ grade of 14 per cent. Mining of the massive orebody is by Mechanised Ramp Cut and Fill (MRCF). A mining recovery of 98 per cent and minimising dilution are primary goals in extracting the high-grade ore. Placing a distinguishable marker bed (working platform) on rock fill was identified as a key method to achieving these goals. Gravel from a pit located onsite was considered the most suitable material for the marker beds. Research undertaken to design the marker beds using the gravel revealed conventional methods used in mining would not suffice, but that road stabilisation methods could be a viable alternative. Trials used a road recycler to mix cement and gravel in situ and several test beds were constructed on the surface to determine the final design. The trials attempted to replicate a marker bed's life cycle of construction and placement and mucking of ore from the marker bed.

Jan 1, 1998

By Theo Lehner

The Rönnskär smelter has wide experience in the field of recycling of non-ferrous metals. Today, smelting and refining from primary and secondary raw materials are integrated in a complex flow sheet. Boliden operates a lead flash smelter, a lead refinery, a copper smelter and refinery, a sulphuric acid and sulphur dioxide plant, a slag fuming plant and precious metal plant at its Rönnskär smelter in the North of Sweden. The Business Area Smelter Operations also incorporates Boliden Bergsöe, Sweden's lead-acid battery recycler, and Norzink, Norway, where recycled zinc accounts for more than 20% of it's production. Raw materials for the Rönnskär smelter include concentrates, ashes, slags, metallic scrap, electronic scrap and electric arc furnace (EAF) steel-making dust. This paper briefly describes current operations and illustrates current measures to improve productivity. Limits to recycling as experienced by a non-ferrous smelter are, illustrated. The deportment of critical elements contained in raw materials is also discussed.

Jan 1, 1998